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23 September 2011<br />

WESTIN GARDEN CITY,<br />

MUMBAI<br />

<strong>Improving</strong> <strong>Equipment</strong> <strong>Availability</strong> <strong>and</strong> <strong>Reliability</strong><br />

<strong>Using</strong> <strong>the</strong> PI System<br />

Presented by: Mr. KP Srivastava - Senior Manager<br />

UltraTech Cement Limited<br />

Unit: Narmada Cement – Jafarabad works<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC 1


Agenda<br />

* PI system in UTCL-NCJW plant network<br />

* Specific Utilization of various PI utilities<br />

* Latest Development<br />

* Problems <strong>and</strong> Limitations<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC<br />

2


Server-1<br />

E<strong>the</strong>rnet<br />

Switch 1<br />

Configuration of PI Network at NCJW<br />

Server-2<br />

E<strong>the</strong>rnet<br />

Switch 2<br />

E<strong>the</strong>rnet to<br />

OFC<br />

converter<br />

OFC to<br />

E<strong>the</strong>rnet<br />

converter<br />

E<strong>the</strong>r<br />

net swt.<br />

PLG server<br />

PLC 1 PLC 2 PLC 3 PLC 4 PLC 5 PLC 6 PLC 7<br />

Fire<br />

wall<br />

QCX server<br />

LAN- PCs<br />

( USERS )<br />

PI server


Business challenge/problem addressed<br />

Process <strong>and</strong> QC data not available to maintenance <strong>and</strong><br />

operation team at <strong>the</strong>ir workplace.<br />

Process <strong>and</strong> QC data have been available in SCADA or Quality<br />

control system server.<br />

Operation <strong>and</strong> maintenance persons has to call to CCR operator<br />

for process data <strong>and</strong> chemist for quality related data. It<br />

creates lot of nuisance which leads to mistakes <strong>and</strong><br />

communications failures.<br />

Solution<br />

Process <strong>and</strong> QC data made available to maintenance <strong>and</strong><br />

operation team at <strong>the</strong>ir workplace through PI System<br />

ProcessBook application.<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC<br />

4


Screen developed by maintenance crue<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC 5


Process view of kiln<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC 6


Process view of Coal Mill<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC 7


Benefits<br />

1. Plant operation <strong>and</strong> Quality related data can be view<br />

by maintenance crew <strong>and</strong> operating crew at <strong>the</strong>ir work<br />

place on <strong>the</strong>ir own PC through LAN connection.<br />

Process flow diagram can be developed for each<br />

section separately <strong>and</strong> process <strong>and</strong> quality parameter<br />

can be shown in flow diagram for better<br />

underst<strong>and</strong>ing.<br />

2. Customized screens can be developed by<br />

maintenance team to monitor <strong>the</strong>ir ownership<br />

equipment related data for better maintenance<br />

practices <strong>and</strong> proactive approach.<br />

3. Nuisance to operator <strong>and</strong> chemist are reduced by<br />

minimizing unnecessary communication <strong>and</strong> chances<br />

of error in verbal communication.<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC 8


Business challenge/problem addressed<br />

2. There is no way to find process <strong>and</strong> quality parameter<br />

after certain time.<br />

Many parameters are required to refer over a period of time for<br />

improvement / analysis purpose. SCADA has limitations <strong>and</strong> it can<br />

save historical data for a small period of time.<br />

Solution<br />

PI Server archived <strong>the</strong> Data in compressed form <strong>and</strong> stored <strong>the</strong> data in<br />

large amount for a longer period. We can get each parameter<br />

value for every second for last 3 years. It can be view in <strong>the</strong> form<br />

of trend or it can be retrieved in <strong>the</strong> excel sheet.<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC 9


Business challenge/problem addressed<br />

3. There is no way to monitor real time data of o<strong>the</strong>r<br />

similar unit.<br />

We do not have <strong>the</strong> system to monitor <strong>the</strong> o<strong>the</strong>r unit parameters for<br />

comparison for improvement projects.<br />

Solution<br />

We can monitor real time <strong>and</strong> au<strong>the</strong>ntic data of all <strong>the</strong> manufacturing<br />

units of Ultratech Cement from any one of <strong>the</strong> manufacturing unit<br />

as well as from head office. DataLink is being used to compare<br />

data in <strong>the</strong> excel sheet. Similar units data are taken on excel sheet<br />

for comparison for bench marking <strong>and</strong> improvement projects.<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC 10


Case study # 1<br />

Application : Cement Bag Counter <strong>and</strong> Dispatch Reconciliation<br />

Before ( Problem ) After ( Solution)<br />

1 Earlier <strong>the</strong>re was no System to reset <strong>the</strong> counter from<br />

site by Dispatch Supervisor(Person of PP operation)<br />

2 Since <strong>the</strong> end of dispatch on daily basis was not<br />

identified at PI, <strong>the</strong> counts were never used to<br />

compare with actual dispatch <strong>and</strong> so <strong>the</strong> use of PI for<br />

bag counts was not effective.<br />

3 The time at which dispatch fininsed changes day to<br />

day basis ,due to nature of operation <strong>and</strong> manual truck<br />

loading .So counter reading based on time ( ideally at<br />

12.0 night )was never in match with dispatch.( Sample<br />

PI Graph enclosed)<br />

4 Two bags going simultaneously <strong>and</strong> counted as one<br />

due to less gap between <strong>the</strong>m. This happens<br />

sometimes due to misoperation /malfuction at packer<br />

Provided <strong>the</strong> Reset switch for counter ,taken into PI<br />

System <strong>and</strong> instructed <strong>the</strong> Supervisor to reset <strong>the</strong><br />

counter at <strong>the</strong> end of each date when dispatch of<br />

<strong>the</strong> date is closed.<br />

Since <strong>the</strong> time at which <strong>the</strong> dispatch is closed is<br />

identified at PI , The counts in it can be used for<br />

comparison with actual dispatch.<br />

Even after change of time from sharp 12.0 night ,<br />

due to operational constraints, <strong>the</strong> end of dispatch<br />

of <strong>the</strong> date can be identified in PI system <strong>and</strong> so <strong>the</strong><br />

bag counts can be compared with actual dispatch.<br />

The problem is overcome by sensitive photosensor<br />

as it can detect even minor gap.( This problem shall<br />

not add in effectiveness of Bag counter system as<br />

in this condition , <strong>the</strong> bag counts will be less than<br />

<strong>the</strong> dispatch by number of times such phenomenon<br />

happened. Since <strong>the</strong> counts are less than actual<br />

dispatch, <strong>the</strong> challenge is over, ). The challenge is<br />

bag count more than <strong>the</strong> actual dispatch*20<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC<br />

11


Cement Bag Counter recorded in PI with reset<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC<br />

12


Case study # 2<br />

<strong>Equipment</strong> name:<br />

Crusher H.T. Motor( B7 )<br />

• Problem Faced<br />

• Whenever H.T. motor gets tripped on Thermal<br />

Overload , Sometimes it was found that <strong>the</strong> current<br />

value in <strong>the</strong> SCADA point trend was normal.<br />

• So it was very difficult to convince <strong>the</strong> MINES as well<br />

as PROCESS dept., that it was an actual tripping due<br />

to rise in current value above specified value.<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC<br />

13


© Copyright 2011 <strong>OSIsoft</strong>, LLC 14


• LIMITATION<br />

• Point trend of any analog value gets updated in <strong>the</strong><br />

present SCADA system after every 10 sec.<br />

• But <strong>the</strong> delay for Thermal Overload tripping of <strong>the</strong><br />

crusher Motor is 3sec.<br />

• So <strong>the</strong> actual current value at <strong>the</strong> time of tripping, is<br />

some times not recorded.<br />

• Advantage of PI System<br />

• Updating time of PI System is 01 sec<br />

• Resolution of PI System is higher than SCADA system.<br />

• The ACTUAL Current Value at <strong>the</strong> time of tripping is<br />

recorded in PI.<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC 15


Ad-Hoc Trend<br />

60<br />

50<br />

40<br />

30<br />

20<br />

10<br />

0<br />

7/27/2008 8:00:00 PM 3.00 hours<br />

7/27/2008 11:00:00 PM<br />

NCJW CRU & REC CURRENT LS CRSHR MOT B7<br />

17.859<br />

A<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC 16


Manual Data entry for QC parameters<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC 17


Connecting PI System with Colony TV Network<br />

Internal LAN Network<br />

PI Server<br />

Plant E<strong>the</strong>rnet Network<br />

PLC<br />

Way forward….<br />

CCR SERVER ROOM TV ROOM<br />

WIRELESS LAN Network<br />

Internal LAN Network<br />

6 Kilometer<br />

PI<br />

Terminal<br />

AGP<br />

CARD<br />

MODULATOR<br />

CABLE<br />

NET WORK<br />

COLONY<br />

TV<br />

TV<br />

TV<br />

18


© Copyright 2011 <strong>OSIsoft</strong>, LLC


23 September 2011<br />

WESTIN GARDEN CITY,<br />

MUMBAI<br />

<strong>Improving</strong> <strong>Equipment</strong> <strong>Availability</strong> <strong>and</strong> <strong>Reliability</strong><br />

<strong>Using</strong> <strong>the</strong> PI System<br />

Presented by: Manu Singh – Senior Engineer (Instrumentation)<br />

UltraTech Cement Limited<br />

Unit: Aditya Cement Works - Shambhupura<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC 20


FLS OPC Server<br />

Crusher OPC Server<br />

CBA OPC Server<br />

LINE-2 OPC Server<br />

EMS OPC<br />

Server<br />

PI System Architecture at Ultratech Cement Ltd<br />

(Aditya Cement Works Shambhupura )<br />

PLC Network<br />

PI-Server<br />

TPP OPC Server<br />

First Unit to use PI System in Cement<br />

Office LAN-<br />

PCs<br />

Web Clients<br />

Office LAN<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC


PI ProcessBook Application<br />

PFCC Cooler Status monitoring<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC


Performance Calculations<br />

Logging of Quality parameters<br />

Generating process log sheets<br />

Logging of Quality lab parameters<br />

Run Hours <strong>and</strong> Batch Counters report<br />

Bag Counter <strong>and</strong> Dispatch report<br />

<strong>Equipment</strong> condition monitoring<br />

Daily power <strong>and</strong> output analysis<br />

Shift Operator Performance report<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC


Logging of Quality Lab Parameters<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC


Packing Plant Bag Counter Report<br />

10 Nos of PI tags + PI DataLink features makes <strong>the</strong> report available on a single<br />

click, By entering date in a cell, history data can be called.<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC


Manual Discharged Bag Counter Report<br />

• Helps while maintaining <strong>and</strong> achieving six- sigma level<br />

• History data can be called by altering date Excel formula<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC


Example 1 : Condition Monitoring<br />

On line monitoring of critical parameters ( Current data )<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC<br />

2


Kiln - Unit 1<br />

Sl.<br />

No<br />

PI Tag No Descriptor<br />

Kiln support Rollers<br />

1<br />

2<br />

3<br />

4<br />

ACS KN TEMP KILN<br />

ROLLER1 1<br />

ACS KN TEMP KILN<br />

ROLLER1 2<br />

ACS KN TEMP KILN<br />

ROLLER1 3<br />

ACS KN TEMP KILN<br />

ROLLER1 4<br />

Kiln main drive & Girth gear<br />

5<br />

6<br />

ACS KN TEMP KN301 MTR<br />

DE BRG<br />

ACS KN TEMP KN301 MTR<br />

NDE BRG<br />

7 ACS KN TEMP KN301 GB 1<br />

8 ACS KN TEMP KN301 GB 2<br />

9 ACS KN TEMP KN301 GB 3<br />

10 ACS KN TEMP KN301 GB 4<br />

Example 2 Condition Monitoring<br />

On line monitoring of critical parameters ( Historic data )<br />

KILN ROLLER BEARING<br />

STATION 1 TEMP-1<br />

KILN ROLLER BEARING<br />

STATION 1 TEMP-2<br />

KILN ROLLER BEARING<br />

STATION 1 TEMP-3<br />

KILN ROLLER BEARING<br />

STATION 1 TEMP-4<br />

Eng<br />

Unit<br />

Alarm 1 Alarm 2 Trip<br />

0C 55 68<br />

0C 55 68<br />

0C 55 68<br />

0C 55 68<br />

KILN MTR 301 DE BRG 0C 75 95<br />

KILN MOTOR 301 NDE<br />

BRG TEMP<br />

KILN GEAR BOX<br />

TEMPERATURE - 1<br />

KILN GEAR BOX<br />

TEMPERATURE - 2<br />

KILN GEAR BOX<br />

TEMPERATURE - 3<br />

KILN GEAR BOX<br />

TEMPERATURE - 4<br />

0C 85 95<br />

0C 75 90<br />

0C 75 90<br />

0C 75 90<br />

0C 75 90<br />

Time of<br />

best<br />

achieved<br />

13-Jan-10<br />

11:42:39<br />

14-Jan-10<br />

11:39:56<br />

14-Jan-10<br />

11:39:56<br />

14-Jan-10<br />

11:39:56<br />

08-Mar-10<br />

07:31:48<br />

14-Jan-10<br />

03:09:28<br />

10-Jan-10<br />

05:24:30<br />

07-Aug-10<br />

16:19:43<br />

14-Jan-10<br />

11:39:56<br />

14-Jan-10<br />

11:39:56<br />

Best<br />

achieved<br />

41.5<br />

31.7<br />

33.3<br />

34.9<br />

40.5<br />

40.2<br />

52.2<br />

47.6<br />

58.5<br />

58.7<br />

1 2 3<br />

45.6<br />

43.1<br />

43.2<br />

48.7<br />

49.3<br />

62.1<br />

60.1<br />

45.3<br />

62.0<br />

64.6<br />

47.1 45.9<br />

44.1 41.6<br />

45.8 42.8<br />

48.4 47.9<br />

49.4 48.1<br />

62.3 59.2<br />

57.8 55.4<br />

44.0 42.5<br />

61.9 59.8<br />

64.9 63.6<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC


CONCLUSIONS<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC


FUTURE PLAN<br />

RC IV at Karnataka<br />

GCR 2 at Raipur<br />

KARUR at TN<br />

Provision of PI-ERP<br />

Connectivity<br />

Migration to PI 2010<br />

Platform<br />

NEW PROJECTS<br />

TO HAVE INTEGRATED<br />

INFO SYSTEMS FROM<br />

DAY 1<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC


© Copyright 2011 <strong>OSIsoft</strong>, LLC


23 September 2011<br />

WESTIN GARDEN CITY,<br />

MUMBAI<br />

Applying PI System – For <strong>Improving</strong> Process<br />

Condition & Process Optimization<br />

Presented by: Lalit Pokharana - Senior Engineer (Instrumentation)<br />

UltraTech Cement Limited<br />

Unit: Kotputli Cement Works ,Raj<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC 32


Agenda<br />

<strong>OSIsoft</strong> products <strong>and</strong> services.<br />

Overview of Kotputli Cement Works.<br />

PI System Architecture at Kotputli Cement Works.<br />

PI Utilization as Kotputli Cement Works.<br />

Business Challenges & solutions.<br />

Examples - Process Optimization.<br />

Case Study – Process Optimization.<br />

Results & benefits.<br />

Future Plans.<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC 33


Overview of Kotputli Cement Works<br />

MTPD Year Status<br />

10,000 2009 Greenfield plant.<br />

PI SYSTEM<br />

INSTALLED IN THE<br />

2011 JAN.<br />

We are committed to Green, Clean <strong>and</strong> Safe environment.<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC 34


PI SYSTEM ARCHITECTURE<br />

A B<br />

E<strong>the</strong>rnet LAN<br />

FIREWALL<br />

SWITCH<br />

Redundant DCS Servers<br />

(5000 Tags)<br />

PI Server<br />

Client 1 Client 2 Client 3 Client 4……… ...Client n<br />

QCX<br />

XRF XRD CBA<br />

Aditya Birla Group<br />

O<strong>the</strong>r Units Remote<br />

PI Server & Client<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC 35


PI Utilization At KOTPUTLI<br />

Functionalities to cover:<br />

•Data extraction (interface)<br />

•Plant configuration <strong>and</strong> templates manager<br />

•Reports generation<br />

•Interfaces to ano<strong>the</strong>r systems (e.g. QCX,XRF,XRD,FUZZY SYSTEM)<br />

•Process scope includes:<br />

Raw mill<br />

Kiln<br />

Coal mill<br />

Cement mill<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC 36


PI Utilization At KOTPUTLI<br />

How we use <strong>the</strong> PI System at our plant<br />

• PI Clients installed in all maintenance departments –<br />

Quality, Production, Mechanical, Electrical, Instrumentation & MID.<br />

• Real time data monitored at Quality Control <strong>and</strong> Mines department.<br />

• Monitoring of o<strong>the</strong>r cement units process parameters.<br />

• SMS notification for real time monitoring of plant running status <strong>and</strong> <strong>the</strong><br />

PGNAA Data to Mines Department in mines area through SMS :-<br />

SiO2=30.66 ,CaO=29.83, MgO=30.34 K2O =15.20,LSF=29.13,Na2O=29.67<br />

Quality has been one of our priorities<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC 37


Business Challenges<br />

•Correlate quality <strong>and</strong> operations data .<br />

•Time to consolidate quality data from lab equipment to mines & process.<br />

•Incorporate quality data to a real-time platform .<br />

•St<strong>and</strong>ardize <strong>and</strong> simplify access to data .<br />

•Reduction of Total Cost.<br />

•Reducing Fossil Fuel & Electric Power costs involves efforts from different<br />

process areas, with <strong>the</strong> majority falling on <strong>the</strong> Cement Making Operations.<br />

•In addition, a better mix of alternative <strong>and</strong> fossil fuels could reduce <strong>the</strong><br />

environmental footprint even more.<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC 38


Business solution<br />

Mining<br />

SIO2 CAO MGO<br />

Mines engineers take<br />

corrective action without<br />

information from QC.<br />

03/11/2009<br />

Crushing<br />

CBA<br />

PI Notification<br />

(SMS ALART)<br />

Stacking &<br />

Reclaiming<br />

Raw Meal<br />

Milling<br />

SiO2=30.66 ,CaO=29.83, MgO=30.34<br />

K2O =15.20,LSF=29.13,Na2O=29.67<br />

QCX<br />

CBA<br />

XRF<br />

Q XRD<br />

Q<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC<br />

39


Results<br />

• Single Platform for Quality <strong>and</strong> Production data .<br />

•St<strong>and</strong>ardization .<br />

•Real-time Quality KPI’s .<br />

•Faster data ga<strong>the</strong>ring process .<br />

•Enhanced data security .<br />

•Easy corporate consolidation .<br />

•Cross business visibility in internal units of grasim.<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC<br />

40


Process Optimization Case Study<br />

• Communication<br />

with Central<br />

Control room<br />

minimized.<br />

• PI DataLink Helps<br />

in breakdown<br />

analysis.<br />

• PI ProcessBook<br />

help in real time<br />

data monitoring.<br />

• Effective<br />

equipment health<br />

monitoring.<br />

• Huge Databank for<br />

analyzing plant<br />

behavior in<br />

different process<br />

conditions.<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC 41


Process Optimization Report<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC 42


Intangible benefits<br />

• Real-time quality measurement results ensure high-quality cement/clinker<br />

production.<br />

• Production <strong>and</strong> quality data correlation .<br />

• Automatically generated notifications at mail & phone(SMS).<br />

• Validated production information; verified data quality; monitoring <strong>and</strong> reporting of<br />

exactly where losses occur; calculation of monthly reconciled recovery .<br />

• Reduction in total energy consumption.<br />

• Integrate X-ray(QCX,XRF,XRD) equipment from different vendors .<br />

• Eliminate risk of technology obsolescence.<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC<br />

43


Future plans <strong>and</strong> next steps<br />

• Connectivity of PI Server over OPC for :<br />

QCX SYSTEM.<br />

Thermal Power Plant.<br />

Energy Management System.<br />

• Linking PI data to SAP.<br />

• Underst<strong>and</strong>ing <strong>and</strong> Implementation of latest <strong>OSIsoft</strong> products.<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC<br />

44


Questions<br />

© Copyright 2011 <strong>OSIsoft</strong>, LLC<br />

45


© Copyright 2011 <strong>OSIsoft</strong>, LLC

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